Method for manufacturing a bottom wear product, particularly a bra

Abstract

To provide a method for manufacturing an underwear product, especially a brassiere requiring no stretch material to reach required durability.SOLUTION: A method for manufacturing a brassiere comprises the steps of: preparing a first fabric layer (11), a second fabric layer (13), and a third material (17): spraying reaction type "hot-melt" polyurethane adhesives to the first fabric layer (11); applying a heat adhesive polyurethane film (17) to the second fabric layer (13); overlapping the two fabric layers (11, 13) together; joining the two fabric layers (11, 13) by high temperature compression, reactivating the reaction type polyurethane adhesives to be temporarily changed into a liquid phase state, and after that, finally causing a cross-linking process for solidifying the adhesives to fix components; and thermoforming a product according to a desired shape.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present invention relates to a method for manufacturing underwear products, particularly bras.

Background Art

[0002] Generally, it is clear that this type of product must have good elastic properties so as to ensure a high level of comfort for the person wearing it and prevent discomfort or skin irritation.

[0003] In order to obtain the desired elastic modulus, elastic fabric pieces are usually used, but such elastic fabric pieces generally cannot guarantee optimal results in terms of comfort, for example, they cannot prevent marks on the skin caused by the pressure generated by such stretchable materials.

[0004] In another example, particularly in the case of a bra formed by two overlapping fabric layers, a silicon element that functions as both an elastic element and a joining element for the two fabric layers may be used.

[0005] However, silicon is often opposed due to the risk of being harmful to health. Furthermore, the use of silicon elements causes problems in the final thermoforming step for shaping the bra into the final form required from the viewpoints of aesthetics and durability. In fact, usually, thermoforming is carried out at a temperature close to 200°C, suggesting the risk of melting the silicon material and consequently damaging the product.

Summary of the Invention

Problems to be Solved by the Invention

[0006] A general object of the present invention is to overcome the above-mentioned drawbacks by providing a method for manufacturing underwear products, particularly bras, which do not require stretchable materials to achieve the required durability.

[0007] A further object of the present invention is to provide a method for manufacturing a bra without using a silicon material.

Means for Solving the Problems

[0008] In view of such an object, according to the present invention, there is provided a method for manufacturing an undergarment product, particularly a bra, - preparing a first fabric layer designed to constitute the outer layer of the undergarment product and cut according to a shape substantially corresponding to the planar projection of the stretched undergarment product; - preparing a second fabric layer designed to constitute the inner layer of the undergarment product and cut according to a shape substantially corresponding to the planar projection of the stretched undergarment product; - preparing a third film material which is a "silicon-free" thermoadhesive polyurethane film designed to constitute a permanent joining element between the first fabric layer and the second fabric layer of the completed undergarment product, and which is cut to form at least one central chest-bottom part, a pair of upper parts arranged corresponding to the shoulder straps of the bra, and a pair of side parts arranged corresponding to the sides of the bra; - spraying a reactive "hot melt" polyurethane adhesive on the side of the first fabric layer facing the second fabric layer, which can be reactivated only once by heating within a reactivation period of at least 3 days, preferably within 5 days from application; - applying the thermoadhesive polyurethane film part in place on the side of the second fabric layer facing the first fabric layer and thermally fusing the part onto the second fabric layer by high-temperature pressing; - overlapping the first and second fabric layers in a state where the side of the first fabric layer covered with the reactive polyurethane adhesive faces the second fabric layer and the thermoadhesive polyurethane film part applied to the second fabric layer faces the first fabric layer; - During the reactivation period of the reactive "hot melt" polyurethane adhesive, the thermoadhesive polyurethane film portion is disposed therebetween to join two fabric layers cut according to their respective shapes by high-temperature pressing, reactivate the reactive polyurethane adhesive, temporarily change it to a liquid phase state suitable for penetrating into the fibers of the fabric to be joined, and then cause a chemical cross-linking process to finally solidify the reactive polyurethane adhesive and permanently fix the components in a final and permanent manner; - At the end of the cross-linking process of the polyurethane adhesive, thermoforming the underwear product according to the desired shape; - Applying shoulder straps, hooks, labels and other possible accessories to finally finish the underwear product. A method comprising the above steps is contemplated.

[0009] Hereinafter, to clarify the innovative principle of the present invention and its advantages over the prior art, one exemplary embodiment applying such a principle will be described while utilizing the accompanying drawings.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Best Mode for Carrying Out the Invention

[0011] The bra according to the manufacturing method of the present invention is of the type composed of two overlapping fabric layers, namely an outer fabric layer having a completely aesthetic function and an inner fabric layer adapted to guarantee high comfort and durability functions for the person wearing it.

[0012] First, it is assumed that the manufacturing method of the underwear product according to the present invention prepares a first fabric layer 11 that is designed to form the outer layer of the bra and is cut according to a shape 12 corresponding to the planar projection of the stretched underwear product, but with slightly larger dimensions than the shape that the product itself must have at the time of completion.

[0013] The "planar projection of the stretched product" in this specification means the shape of the product (or a part thereof) spread out on a plane. Substantially, such a shape corresponds to what is known as a "paper pattern" in the sewing / fashion industry, that is, the shape that needs to be used as a reference for cutting the fabric to create clothes.

[0014] The manufacturing method according to the present invention further assumes preparing a second fabric layer 13 that is designed to form the inner layer of the bra and is cut according to a shape 14 substantially corresponding to the planar projection of the stretched underwear product.

[0015] Therefore, the first fabric layer 11 will have slightly larger dimensions than the second fabric layer 13.

[0016] The first and second fabric layers 11, 13 can be provided as a continuous piece or in the form of cut pieces of the finished size according to specific organizational requirements of the production site. Figures 1 and 2 schematically show fabric pieces or cut pieces 15, 16 from which the shapes 12, 14 are respectively cut out.

[0017] The type of material constituting the first fabric layer 11 is basically selected based on the desired aesthetics of the product. For example, such materials can be selected from lace, tulle, microfiber, silk, stretch cotton, etc.

[0018] The type of material constituting the second fabric layer 13 is basically selected based on the desired comfort and durability of the product. For example, such materials can be selected from microfiber, tulle, silk, stretch cotton, etc.

[0019] The manufacturing method according to the present invention further assumes preparing a third film material 17 designed to constitute a permanent joining element between the first fabric layer 11 and the second fabric layer 13 of the finished underwear product.

[0020] As schematically shown in Figure 3, this third film material 17 is cut into a shape suitable for forming at least one central chest-bottom part 18, a pair of upper parts 19, 19' arranged corresponding to the shoulder straps of the bra, and a pair of side parts 20, 20' arranged corresponding to the sides of the bra.

[0021] The film material 17 used to constitute the permanent joining element between the first fabric layer 11 and the second fabric layer 13 is a "silicone-free" thermally adhesive polyurethane film material.

[0022] The heat - adhesive polyurethane film advantageously uses two materials of different weights: a so - called "heavy" first material for forming the central chest - bottom part 18 and the upper strap parts 19, 19', and a so - called "light" second material for forming the side parts 20, 20' which are thinner and lighter per square meter than the first material.

[0023] Specifically, for the "heavy" heat - adhesive polyurethane film, a film having a thickness of 180 μm and a weight of 210 g / m 2 can be used, and for the light heat - adhesive polyurethane film, a film having a thickness of 75 μm and a weight of 90 g / m 2 can be used.

[0024] For example, it has been found that for these two types of heat - adhesive polyurethane materials, it is optimal to use films manufactured by FaitPlast known as "Easy - Tech1381" and "Easy - Tech897" respectively.

[0025] The supply, preparation, and cutting of the first and second fabric layers 11, 13 and the heat - adhesive polyurethane film 17 can be carried out simultaneously according to the operating characteristics of the production factory, or a specific order can be assumed without departing from the scope of the innovative principle of the present invention.

[0026] The manufacturing method according to the present invention further includes a step of spraying a reactive "hot - melt" polyurethane adhesive (PUR) that can be reactivated only once by heating within a reactivation period of at least 3 days from application, preferably within 5 days from application, on the inner side of the first fabric layer 11 (i.e., the side that will face the second fabric layer 13).

[0027] The application of the adhesive onto the fabric is carried out at a high temperature of about 140 °C so that the adhesive is in a liquid state. The adhesive spread on the fabric becomes solid after about 30 seconds and remains in this state until subsequent reactivation.

[0028] For this purpose, it has been found that the use of a reactive polyurethane adhesive known as "Kleiberit 900.7.9967" manufactured by Kleiberit is particularly advantageous.

[0029] The adhesive can be applied to the first fabric layer 11 before or after cutting the fabric according to shape 12, in accordance with the operating characteristics of the production plant.

[0030] The manufacturing method according to the present invention further assumes that the aforementioned central chest bottom portion 18, upper shoulder strap portions 19, 19' and side portions 20, 20' formed of the thermally adhesive polyurethane film 17 are applied to the correct positions on the inner side of the second fabric layer 13 (i.e., the side that is to face the first fabric layer 11) as shown in FIG. 4, and the portions are heat-sealed onto the fabric layer 13 using high-temperature pressing at a temperature of about 160°C for about 15 to 20 seconds, preferably 16 seconds.

[0031] When the portions 18, 19, 19', 20, 20' are fixed to the fabric layer 13, as is well known to those skilled in the art, the protective support of the thermally adhesive polyurethane film 17 is removed, leaving only the elastic portion of the polyurethane film 17 bonded to the fabric layer 13.

[0032] After performing the operations described so far, provided that the "hot melt" reactive polyurethane adhesive is still reactivatable, the joining of the two fabric layers 11, 13 with the portions 18, 19, 19', 20, 20' of the thermally adhesive polyurethane film 17 disposed therebetween (previously cut according to the respective shapes 12, 14) can be started until the parts are finally and permanently fixed.

[0033] To perform the step of joining the two fabric layers 11, 13, the first fabric layer 11, which is to form the outer layer of the bra, is placed on a plane with the side covered with the reactive polyurethane adhesive facing up, and the second fabric layer 13, which is to form the inner layer of the bra, is placed on the first fabric layer 11 while taking care that the shape 14 of the second fabric layer 13 fits into the shape 12 of the first fabric layer 11 with the portion of the thermoadhesive polyurethane film 17 facing down.

[0034] In this way, the portions 18, 19, 19', 20, 20' of the thermoadhesive polyurethane film 17 are correctly positioned between the two fabric layers 11, 13.

[0035] Thereafter, the assembly of the two fabric layers 11, 13 with the thermoadhesive polyurethane film 17 intervening therebetween is advantageously covered with a paper sheet 21 as shown in FIG. 5, and this function will be described later.

[0036] At this point, high-temperature pressing of the two overlapping fabric layers 11, 13 is performed. Due to the above-described properties of the adhesive used, this operation may be performed within 5 days from the application of the adhesive itself.

[0037] To perform this operation, the assembly of the overlapping fabric layers 11, 13 covered with the layer of the protective paper 21 with the thermoadhesive polyurethane film 17 intervening therebetween is placed under the plane of a high-temperature pressing machine that heats the material to about 120°C for at least 10 seconds.

[0038] Such heating reactivates the "hot melt" reactive polyurethane adhesive (PUR), returning it to a liquid state and allowing it to penetrate the fibers of the fabric to be joined. The reaction of this adhesive first forms a first mechanical "grip" step and then further initiates a chemical cross-linking process that finally solidifies the adhesive, making it impossible to remove the adhesive itself unless the two edges of the fabric are mechanically peeled off. The complete cross-linking of the type of adhesive used in the manufacturing method according to the present invention takes about 7 days.

[0039] The paper sheet 21 has the function of preventing the adhesive from sticking to the plane of the press at the edges of the first fabric layer 11 that exceed the shape 14 of the second fabric layer 13 during the heating step in the press and during the resulting liquefaction of the "hot melt" polyurethane adhesive.

[0040] When the execution of the high-temperature pressing of the two overlapping fabric layers 11, 13 is completed, the paper sheet 21 is removed, and the second fabric layer 13 partially covers the first fabric layer 11, and a lingerie product as shown in FIG. 6 appears, in which portions 18, 19, 19', 20, 20' of the thermally adhesive polyurethane film 17 are arranged between the two fabric layers 11, 13. Considering that, as seen so far, the first fabric layer 11 is initially formed with dimensions slightly exceeding those of the second fabric layer 13, at this point, the lingerie product temporarily has the surplus peripheral edge 22 formed by the first fabric layer 11.

[0041] When at least 7 days have elapsed since the high-temperature pressing (i.e., the time required to ensure the complete cross-linking of the polyurethane adhesive), the product is thermoformed to give the bra the desired shape and cup size. Such a process is well known to those skilled in the art and will not be described in detail herein.

[0042] At this point, the surplus edge 22 of the first fabric layer 11 is cut off according to the outer shape of the completed garment (also according to techniques and methods well known to those skilled in the art).

[0043] Finally, through normal sewing operations, the application of adjustable shoulder straps, hooks, labels, etc. can be continued to finally complete the clothing.

[0044] At this point, it is clear how the method for manufacturing the underwear product according to the present invention can obtain clothing with the best durability without using stretchable materials or silicon-based materials.

[0045] Naturally, the description of the embodiments applying the innovative principles of the present invention described above is shown as an illustrative example of such innovative principles, and thus should not be construed as limiting the scope of the claims in this application.

[0046] For example, in addition to the portions 18, 19, 19', 20, 20' of the polyurethane thermal adhesive film 17 designed to form the joint of the two fabric layers 11, 13, additional portions can also be provided at appropriate positions according to specific aesthetics and / or functionality that may sometimes be desired or required.

[0047] Furthermore, the shape of the clothing and the fabric constituting it can also be selected based on specific desired characteristics.

Claims

1. A method for manufacturing a bra, preparing a first fabric layer (11) designed to form the outer layer of the bra and cut according to a shape (12) substantially corresponding to the planar projection of the stretched bra; preparing a second fabric layer (13) designed to form the inner layer of the bra and cut according to a shape (14) substantially corresponding to the planar projection of the stretched bra; preparing a third film material (17) designed to form a permanent joining element between the first fabric layer (11) and the second fabric layer (13) of the completed bra, the third film material (17) being a "silicone-free" thermoadhesive polyurethane film and being cut to form a portion composed of at least one central chest bottom portion (18), a pair of upper portions (19, 19') arranged to correspond to the shoulder straps of the bra, and a pair of side portions (20, 20') arranged to correspond to the sides of the bra; spraying a reactive "hot melt" polyurethane adhesive on the side of the first fabric layer (11) facing the second fabric layer (13), the adhesive being reactivatable only once by heating within a reactivation period of at most 3 days from application; applying the portion (18, 19, 19', 20, 20') of the thermoadhesive polyurethane film to the side of the second fabric layer (13) facing the first fabric layer (11) and thermally fusing the portion onto the second fabric layer (13) by high temperature and pressure; The side of the first fabric layer (11) covered with the reactive "hot melt" polyurethane adhesive faces the second fabric layer (13), and the portions (18, 19, 19', 20, 20') of the thermoadhesive polyurethane film applied to the second fabric layer (13) face the first fabric layer (11), and the first and second fabric layers (11, 13) are overlapped; During the reactivation period of the reactive "hot melt" polyurethane adhesive, the portions (18, 19, 19', 20, 20') of the thermoadhesive polyurethane film are disposed therebetween and the two fabric layers (11, 13) cut according to the respective shapes (12, 14) are joined by high temperature and pressure to reactivate the reactive "hot melt" polyurethane adhesive and temporarily change it to a liquid phase state suitable for penetrating into the fibers of the two fabrics to be joined, and then a chemical cross-linking process is caused to finally solidify the reactive "hot melt" polyurethane adhesive to finally and permanently fix the parts; At the end of the chemical cross-linking process of the reactive "hot melt" polyurethane adhesive, the bra is heat formed according to a desired shape; Applying shoulder straps, hooks, labels and other possible accessories to finally finish the bra; A method for manufacturing a bra, characterized by including the above steps.

2. The thermoadhesive polyurethane film (17) is supplied at a first weight to form the central chest bottom portion (18) and the pair of upper portions (19, 19'), and is supplied at a second weight to form the side portions (20, 20'); The method for manufacturing a bra according to Claim 1.

3. The thermoadhesive polyurethane film with the first weight has a thickness of 180 microns and a weight of 210 g / m 2 and the thermoadhesive polyurethane film with the second weight has a thickness of 75 microns and a weight of 90 g / m 2 having the weight of The method for manufacturing a bra according to claim 2.

4. The portion (18, 19, 19', 20, 20') of the thermoadhesive polyurethane film is heat-sealed onto the second fabric layer (13) by high-temperature pressing at a temperature of about 160°C for about 15 to 20 seconds. The method for manufacturing a bra according to claim 1.

5. The spraying of the reactive "hot melt" polyurethane adhesive onto the first fabric layer (11) is carried out at a temperature of about 140°C. The method for manufacturing a bra according to claim 1.

6. The joining of the two fabric layers (11, 13) with the portion (18, 19, 19', 20, 20') of the thermoadhesive polyurethane film disposed therebetween is performed by high-temperature pressing at a temperature of about 120°C for at least 10 seconds. The method for manufacturing a bra according to claim 1.

7. The second fabric layer (13) is cut according to a shape (14) having dimensions substantially corresponding to the shape that the bra should have when completed, and the first fabric layer (11) is cut according to a shape (12) slightly larger than the shape that the bra should have when completed. The method for manufacturing a bra according to claim 1.

8. The superimposition of the first and second fabric layers (11, 13) with the portion (18, 19, 19', 20, 20') of the thermoadhesive polyurethane film disposed therebetween is performed by holding the shape (14) of the second fabric layer (13) within the shape (12) of the first fabric layer (11), thereby defining the surplus peripheral edge portion (22) of the first fabric layer (11). The method for manufacturing a bra according to claim 7.

9. The surplus peripheral edge portion (22) is cut off according to the outer shape of the completed bra after the thermoforming of the bra according to the desired shape. The method for manufacturing a bra according to claim 8.

10. During the pressure heating step and as a result of the liquefaction of the reactive "hot melt" polyurethane adhesive, the entire two fabric layers (11, 13) in which the portions (18, 19, 19', 20, 20') of the thermoadhesive polyurethane film are arranged according to the respective shapes (12, 14) are covered with a protective paper sheet (21) so as to prevent the reactive "hot melt" polyurethane adhesive corresponding to the surplus peripheral edge portion (22) of the first fabric layer (11) on which the adhesive is sprayed from adhering to the plane of the press before the high-temperature pressing. The method for manufacturing a bra according to claim 8.

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